Control module for DC power network

ABSTRACT

A power distribution and control module includes a digital data processor and associated memory module operating an energy management program or schema and a battery charging manager program thereon. The energy management schema is operable to determine an instantaneous configuration of the power and distribution and control module, to determine total instantaneous input power available, total instantaneous power demand by connected power loads and to allocate a portion of the input power to power the loads. Thereafter any unallocated power is allocated to charge rechargeable batteries using allocation criteria that are situationally variable.

1 CROSS REFERENCE TO RELATED U.S. PATENT APPLICATIONS

The present application is a continuation of non-provisional U.S. patentapplication Ser. No. 15/524,826 filed May 5, 2017, entitled CONTROLMODULE FOR DC POWER NETWORK, which is a National Phase application ofPatent Cooperation Treaty International Application No.PCT/US2015/059712 filed on Nov. 9, 2015, which claims priority toprovisional U.S. Patent Application Ser. No. 62/077,993 filed Nov. 11,2014, entitled POWER DISTRIBUTION SYSTEM, and to provisional U.S. PatentApplication Ser. No. 62/168,992 filed Jun. 1, 2015, entitled CONTROLMODULE FOR DC POWER NETWORK, each of which is incorporated herein byreference in their entirety and for all purposes.

2 COPYRIGHT NOTICE

A portion of the disclosure of this patent document may contain materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent files or records, but otherwise reserves all copyrightrights whatsoever. The following notice shall apply to this document:Copyright© Protonex Technology Inc. 2015.

3 BACKGROUND OF THE INVENTION 3.1 Field of the Invention

The exemplary, illustrative technology herein relates to DC powernetworks that utilize smart rechargeable DC batteries and or dumbbatteries connected to the DC power network over a smart cable oradaptor. More specifically the exemplary, illustrative technology hereinrelates to a battery charging manager operable on a DC power network.

3.2 The Related Art

Portable consumer electronic devices such as cell phones, computers,power tools, and the like are more and more powered by rechargeabledirect current (DC) batteries that require frequent recharging. It is atypical problem that DC power is not readily available without a powerconverter that converts high voltage Alternating Current (AC) powersignals such as grid or wall socket power to a lower voltage DC powersource usable to recharge a rechargeable DC battery. The problem isfurther complicated when different DC battery types have differentcharging power requirements, e.g. different operating voltages anddifferent current limits such that even if one has a power adaptor it isusually only compatible with a single rechargeable battery type or asingle portable power device. As a result, consumers often own adifferent AC to DC power converter for every portable electronic devicethey own.

In specialized fields such as the military, public safety, healthcare,building construction, or the like the number of different DC batterytypes and power adaptors has become problematic to business owners andusers who are required to maintain a huge inventory of rechargeablebatteries and associated battery charging hardware. Moreover the workperformed in these specialized fields is often in off-grid locationswhere AC grid power is not always available or reliable. As a result,workers are often forced to scavenge DC power from any available powersource to recharge batteries and these may include recharging fromvehicle batteries or vehicle power generators, recharging using portablephotovoltaic devices, portable wind turbines, portable fuel cells, orother portable power sources, including gasoline powered electricalpower generators.

In addition to the problem that each different battery type hasdifferent electro-mechanical charging interface equipment, manyrechargeable DC batteries are smart batteries that store powerinformation in digital format on the battery. The power informationusually includes a battery type, the battery operating voltage ranges,the peak and average power amplitude that can be delivered by thebattery, battery capacity (e.g. measured in watt-hours (Wh) orampere-hours (Ahr)), a State of Charge (SoC), use time remaining, or thelike, that relates to what portion of the battery capacity is stillusable or how much battery use time is remaining, which indicates howmuch longer the battery can be used before its present charge capacityis used up), and other information such as charging voltage, chargingcurrent limits, or the like. In addition when the smart battery ispaired with a particular device such as a particular cell phone or otherelectronic device, or more generally a specific power load, the powerinformation stored on the smart battery may also include powerinformation specific to the power load such as average and peak powerload drawing by the power load. While power information stored on smartbatteries or smart cables is intended to be read by a DC batterycharger, different rechargeable batteries can store the powerinformation in different formats and or use different network protocolsto communicate with connected DC power chargers or the like.

Accordingly there is a need in the art to improve the utilization andmanagement of rechargeable DC batteries such as by sharing DC poweravailable from a plurality of DC batteries with a variety of power loadsand to take advantage of a wider variety of input DC power sources torecharge DC batteries and power loads that include a rechargeable DCbattery or a smart cable.

One conventional man-portable DC power manager disclosed in related U.S.Pat. No. 8,775,846 to Robinson et al., issued Jul. 8, 2014, entitledPORTABLE POWER MANAGER HAVING ONE OR MORE DEVICE PORTS FOR CONNECTINGWITH EXTERNAL POWER LOADS discloses a charging method characterized bycharging the most-full battery first and draining the least full batteryfirst. More specifically when input power is not available and the onlyavailable power is from rechargeable batteries connected to the powermanager, the power manager operates to select the rechargeable batteryhaving the lowest state of charge as a primary source, which is thenused to power loads as needed until it is fully discharged. Thereafterthe power manager again operates to select the rechargeable batteryhaving the lowest state of charge as a primary source, which is thenused to power loads as needed until it is fully discharged. Similarlywhen input power becomes available, the power manager operates to selectthe rechargeable battery having the highest state of charge to chargefirst until it is fully charged, and then selects and charges thebattery with the next highest state of charge until it is fully chargedbefore charging other batteries.

One problem with the charging methods disclosed by Robinson et al. in'846 is that power is not uniformly distributed amongst connected DCbatteries, leaving some batteries fully discharged at a critical timewhen input power availability is limited and recharging the most fullycharged batteries first when input power becomes available. Moreover themethods disclosed by Robinson et al. in '846 fail to take batterycapacity and or battery use time remaining into consideration whenselecting which batteries to discharge or recharge. For example, a largecapacity battery having a low state of charge may actually providelonger use time than a smaller capacity battery having a higher state ofcharge. Thus there is a need in the art to improve utilization of thecollective start of charge and or remaining use time a DC power networkas a whole to avoid fully discharging and or fully charging one batteryat a time to avoid leaving some power loads without power.

4 SUMMARY OF THE INVENTION

The present invention addresses the problems with conventional DC powersystems and associated rechargeable DC batteries described above byproviding a more robust power distribution and control module. Theimproved power distribution and control module is configured toelectrically interface and communicate with one or more DC power sourcesoperably connected to input device ports and with a plurality of DCpower loads operably connected to output device ports. The power sourcesand the power loads may include one or more rechargeable DC batterieseither as standalone batteries or batteries associated with and poweringa DC power load.

In particular the present invention provides a method for allocatingelectrical power received from external DC power sources to a pluralityof external DC power devices according to various power allocationcriteria. The method includes operating an energy management schema anda battery charging manager module using a controller data processingdevice. The controller data processing device periodically polls eachdevice port to determine an instantaneous configuration of the powerdistribution and control module and then to group the instantaneousconfiguration by device type and other grouping criteria. Based on datareceived from or read from external power devices or measured by powersensors associated with device ports connected to external powerdevices, the processor determines a total instantaneous input poweravailable from one or more DC power sources connected to the powerdistribution and module over one or more device ports. Additionally theprocessor determines a total instantaneous power demand or loadassociated with the plurality of external DC power devices connected todevice ports. In particular the instantaneous power load associated withexternal power devices includes any combination of DC power loads,standalone rechargeable DC batteries and DC power loads that are poweredby rechargeable DC batteries. In addition any internal power loadsassociated with operating the robust power distribution and controlmodule are taken into account and allocated power from the totalinstantaneous input power available.

In a first step the processor/energy management schema allocates powerto any internal power loads. In a second step the processor/energymanagement schema allocates some or all of the remaining totalinstantaneous input power to DC power loads. In a default embodiment,each DC power load is allocating enough power to meet its peak powerdemand or load. After allocating instantaneous input power to internaland external DC power loads any remaining portion of the totalinstantaneous input power is designated as Total Charging Power (TCP)which is allocated to the one or more of the plurality of rechargeableDC batteries that are connected to the power distribution and controlmodule according to allocation criteria operating on the batterycharging manager module. The processor/battery charging manager moduleis further operable to determine the instantaneous State of Charge (SoC)of each rechargeable DC battery connected to the power distribution andcontrol module and the Average State of Charge (ASoC) of some or all ofthe rechargeable DC batteries connected to the power distribution andcontrol module wherein in the ASoC is based on the instantaneous stateof charge (SoC). In a preferred operating mode, the allocation criteriaare configured to allocate the TCP in a manner that tends to equalizethe SoC of each of the plurality of rechargeable DC batteries. In otheroperating modes the allocation criteria are configured to allocate ahigher percentage of the instantaneous TCP to rechargeable DC batterieshaving an instantaneous SoC that is less than the ASoC.

5 BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention will best be understood from adetailed description of the invention and example embodiments thereofselected for the purposes of illustration and shown in the accompanyingdrawings in which:

FIG. 1 depicts a non-limiting exemplary schematic diagram of a portableDC power network according to the present invention.

FIG. 2 depicts a non-limiting exemplary schematic diagram depicting afirst embodiment of a DC power distribution and control system accordingto the present invention.

FIG. 3 depicts a non-limiting exemplary schematic diagram depicting asecond embodiment of a DC power distribution and control systemaccording to the present invention.

FIG. 4 depicts a non-limiting exemplary schematic diagram depictingelements of a smart DC power device electrically interfacing with adevice port of a DC power distribution and control system according tothe present invention.

FIG. 5 depicts a non-limiting exemplary flow diagram depicting powerallocation steps performed by an energy management schema programoperating on a controller data processing device of a DC powerdistribution and control system according to the present invention.

FIG. 6 depicts a non-limiting exemplary flow diagram depicting powerallocation steps performed by a battery charging manager programoperating on a controller data processing device of a DC powerdistribution and control system according to the present invention.

6 DEFINITIONS

TERM DEFINITION Smart A rechargeable DC battery configured to storepower rechargeable information about the rechargeable DC battery and orDC battery about a DC power load being powered by the smart DC batteryin a digital format that is readable by other smart devices. StandaloneA rechargeable DC battery that is not associated with a rechargeableparticular power load. DC battery Peak power The highest DC power loadthat a DC power device is load expected to draw at a given instance.

6.1 Item Number List

The following item numbers are used throughout, unless specificallyindicated otherwise.

# DESCRIPTION 100 DC Power network 110 Soldier power manager 115 Deviceport 117 Electronic enclosure 120 Wire cable 130 DC power load 140 DCpower load 150 DC power load 160 DC power load 170 DC power source 180DC power source 200 Power distribution and control module 210 Power bus220 Controller data processing device 225 Controller network interfacedevice 230 Controller memory module 231 Power channel 232 Power channel233 Power channel 234 Power channel 235 Power channel 236 Power channel240 Controllable switching element 241 DC to DC power converter 242 DCto DC power converter 243 DC to DC power converter 244 DC to DC powerconverter 245 DC to DC power converter 246 Controller network interfacedevice 247 Communication channel 248 Communication channel 252Electrical sensor 254 Electrical sensor 256 Electrical sensor 258Electrical sensor 260 Electrical sensor 262 Electrical sensor 270 Userinterface device 285 Internal power load 300 Power distribution andcontrol module 305 Input device port 310 Output device port 315 Powerdistribution network 320 Electronic control module 325 Controller dataprocessing device 330 Controller memory module 335 Controller networkinterface device 340 DC power source 345 DC power load 350 Input powersensor 355 Output power sensor 360 DC to DC power converter 365 Inputterminal 370 Output terminal 375 Communication channel 385 Internalpower load 390 Controllable switch 395 User interface device 397 Powerpoint tracking module 400 Power distribution and control module 402Electrical power connector 404 Electrical power connector 405 Deviceport 406 I/O port 407 I/O port 408 Communication channel 410 Externalpower device 412 Smart rechargeable DC battery 415 Smart wire cable orsmart adapter 420 Power channel 421 Power channel 425 Controller networkinterface device 430 Controller data processing device 435 Controllermemory 440 Power sensor 445 Controllable switching element 446 DC to DCpower converter 450 Battery data processing device 450a Cable dataprocessing device 455 Battery memory 455a Cable memory module 460Battery network interface device 460a Cable network interface device 465DC Power load 470 Chemical energy storage device 475 Power channel 476Power channel 500 Flow diagram 505 Map DC network 510 Determineinstantaneous input and output power 515 Rank devices according todevice priority 520 Allocate power to DC power loads 600 Flow diagram605 Determine TCP 610 Determine SoC for all DC batteries 615 CalculateASoC 620 Order DC batteries by SoC low to high 625 Allocation loop 630Set counter 635 Compare Bi to ASoC 640 Charge Bi 645 Reduce TCP 650 IsTCP < 0 655 Increase counter 660 Is counter < N 665 Charge uncharged DCbatteries

7 EXEMPLARY SYSTEM ARCHITECTURE 7.1 Power Distribution and ControlModule Having a Power Bus

Referring now to FIG. 1, a first exemplary portable DC power network(100) according to the present invention includes a soldier powermanager (110), described below as a power distribution and controlmodule (200) configured to electrically interface with a plurality ofexternal DC power devices. In the present non-limiting exemplaryembodiment the soldier power manager (110) is carried by an infantrysoldier, e.g. attached to the uniform worn by or the pack carried by thesoldier. The plurality of external power devices include various DCpower loads (130, 140, 150, 160) and one or more DC power sources (170)and or (180), not all of which are necessarily connected at the sametime. Example soldier power manager devices and operating methods aredescribed in commonly assigned U.S. Pat. No. 8,775,846, entitledPORTABLE POWER MANAGER, U.S. Pat. No. 8,638,011, entitled PORTABLE POWERMANAGER OPERATING METHODS, U.S. Pat. No. 8,633,619, entitled POWERMANAGERS AND METHODS FOR OPERATING POWER MANAGERS, and in U.S. Pat.Appl. Pub. No. 20140103720A1, entitled POWER MANAGERS AND METHODS FOROPERATING POWER MANAGERS, all by Robinson et al. and all of which areincorporated herein by reference in their entirety for all purposes.

The external power devices include one or more DC power loads such aswireless communications devices, a navigation device and a night visionsystem. Generally a power load consumes electrical power to perform atask. Typically each DC power load (130, 140, 150, 160) includes its ownrechargeable DC battery associated therewith, often mounted inside ahousing of the external DC power load. Preferably the rechargeable DCbattery is a smart battery that includes a digital communicationinterface (e.g. a network interface device) and at least a programmableor non-volatile memory module provided on the smart battery to storedigital information related to the battery itself and or related to theload being powered by the battery. Typically the stored digitalinformation includes power characteristics of the load and therechargeable battery in a format that is readable by the soldier powermanager (110).

In some cases the soldier power manager (110) is used to rechargerechargeable DC batteries that are standalone devices not associatedwith or actively powering a power load. In such cases only the DCbattery is connected to a device port and all power delivered to the DCbattery by the soldier power manager (110) is substantially stored bythe standalone battery. In other example operating modes, a rechargeableDC battery is electrically interfaced to a device port and a power loadis electrically interfaced with a DC battery. In such cases, the powerload, when set in a non-operating mode, may cause the associatedrechargeable DC battery to be treated like a standalone rechargeable DCbattery.

In one example use scenario, a reliable DC power source becomesavailable and is connected to an input port of the soldier power manager(110). Thereafter a user or a plurality of users connects a plurality ofstandalone rechargeable DC batteries to the soldier power manager (110)for rapid recharging. Thus depending on configurations and operatingmodes of external DC power devices, which can be changed by a user, anexternal power load connected to a device port can be characterized as apower load or as a standalone rechargeable DC battery and the energymanagement schema of the present invention treats these two casesdifferently.

The external power devices also include one or more DC power sources(180) such as an electrochemical power generator or fuel cell, aportable mechanical power generator such as a portable wind or portablewater turbine, a fossil fuel powered engine, or the like, driving a DCpower generator, an electrically powered DC power generator, e.g. a DCpower converter connected to an AC power grid, or the like. Additionallyany electrochemical energy storage device such as any one of the smartrechargeable DC batteries described above, a vehicle battery system, orthe like, are also usable as a DC power source (170) operable to deliverinput power to the soldier power manager (110).

In the present first example embodiment the soldier power manager (110)includes a plurality of device ports (115) and each external powerdevice is electrically interfaced to the soldier manager (110) by a wirecable (120) or adaptor, electrically interfaced to one of the deviceports (115). The wire cable includes an electrical connector at each endthereof, not shown, with one end of the wire cable (120) configured toelectrically interface with a device port (115) and an opposing end ofthe wire cable (120) configured to electrically interface with a portprovided on the external power device, not shown. Preferably portsprovided on external power devices are input output (I/O) interfaceports having a bidirectional power channel and a bidirectional digitalcommunication channel; however, as will be described below, otherconfigurations are usable without deviating from the present invention.

Referring now to FIG. 2, a non-limiting first exemplary powerdistribution and control module (200) according to the present inventionis shown schematically. The power distribution and control module (200)comprises electrically conductive conduits and electrical controlelements (circuit elements) suitable for exchanging electrical power andcommunication signals with external power devices connected to the powerdistribution and control module (200) over device ports.

Preferably the actual hardware making up the power distribution andcontrol module (200) is housed inside a weather proof portableelectronic enclosure (117), shown in FIG. 1, that includes six deviceports labeled (1-6). Each device port (1-6) comprises an electricalconnector mechanically installed through and structurally supported by awall of the electronic enclosure (117) such that each device portprovides an electrical interface for connecting an external power deviceto the power distribution and control system (200) using a wireconnector that includes a power channel. Preferably, all the device portconnectors are multi-pin connectors of the same type; however, thenumber of pins and the functionality of each multi-pin connector mayvary from port to port. Any number of device ports greater than two isusable without deviating from the present invention. Additionally,different connector configurations may be provided in alternateembodiments. In other alternate embodiments, device ports may have avariety of different connector configurations, including wirelessoptions such as providing an electrical power interface acrosscontacting conductive contact pads, providing an electrical powerinterface across wireless inductive energy transfer terminals, providingprinted circuit runs or traces on a support substrate, and providingwireless communication interfaces and other electrical interfaces,without deviating from the present invention. In the power distributionand control module (200), each device port (1-6) connects to a commonelectrical conductor such as a power bus (210). Other power distributiontopologies such as star network, chain or mesh network, or the likeusable to connect each of the six device ports to a common conductor areusable without deviating from the present invention.

The power distribution and control module (200) includes a controllerdata processing device (220) and associated controller memory module(230). The controller data processing device (220) and controller memorymodule (230) are preferably housed inside the electronic enclosure (117)and in some embodiments the controller memory module (230) may beincorporated within the controller data processing device (220) or maycomprise a removable memory device removable from the electronicenclosure (117) by a user. In any case at least a portion of thecontroller memory is preferably non-volatile. Example controller dataprocessing devices (220) include a central processing unit (CPU), anintegrated microprocessor, a microcontroller, or a field-programmablegate array (FPGA). Other local and or distributed digital data controlsystems or system elements are usable without deviating from the presentinvention. An example electronic enclosure (117) comprises a lightweight metal or plastic housing formed with water tight seams andconfigured with electro-magnetic wave shielding and electrical groundingelements.

The controller data processing device (220) is electrically connectedwith elements of the power distribution system and connects with each ofthe device ports (1-6) through a controller network interface device(246) or other digital communications interface. A communication channel(248), shown as a broken line, interconnects the controller networkinterface device (246) with each of the device ports (1-6). In alternateembodiments the controller network interface device (246) isincorporated within the controller data processing device (220). Thecommunication channel (248) extends through each device port andpreferably extends through a wire cable (120) connected to the deviceport to an I/O port of an external power device connected to the deviceport over the wire cable, detailed below and shown in FIG. 4. Thus thecommunication channel (248) associated with each device port iselectrically interfaced with the controller data processing device (220)operating on the power distribution and control module (200) and with anexternal digital data memory and or external digital processing deviceoperating on or associated with whatever external power device iselectrically interfaced to the device port.

Preferably, each external power device connected to each device port isa smart device or is connected to the device port over a smart cablewherein the smart device and or the smart cable includes an externaldigital data interface such as an external digital processor, anexternal digital memory, and or the like, readable by or otherwise incommunication with the controller data processing device (220). Ideallythe device type and power and operating characteristics of each externaldevice are stored on the external digital data interface in a formatthat is readable by the controller data processing device (220).

7.1.1 Operating Mode

In a non-limiting operating mode example, the controller data processingdevice (220) periodically maps the power network by polling each deviceport to determine if an external power device is connected to the deviceport and if so to determine a device type, such as, a power load, apower source, or a rechargeable battery, or a combination, and todetermine power characteristics of each external power device such asits operating voltage, peak and average power demand or peak and averagepower availability, for a power source, and other data such as forrechargeable DC batteries the battery charge storage capacity, its Stateof Charge (SoC), and various charging parameters. Once the networkconfiguration is known, an energy management program or schema operatingon the controller data processing device (220) configures elements ofthe power distribution and control module (200) to receive input powerfrom connected power sources and to distribute output power to connectedpower loads and or rechargeable DC batteries. The DC network isperiodically remapped (e.g. at a refresh rate such as every 20 to 100msec), and power is redistributed as needed as network conditionschange.

In a preferred embodiment, the controller data processing device (220)communicates with operably connected power devices and smart cablesusing network packeted data using the SMBus network protocol, which iswidely used to store power characteristic information on smart powerdevices. Additionally, the controller network interface device (246) oradditional controller network interface devices can support othercommunication protocols on a common bus controller to communicate withexternal power devices using other communication protocols such as theInter-Integrated Network (IIC) communication protocol or the UniversalSerial Bus (USB) communication protocol. In some embodiments, the powerdistribution and control module (200) may include wireless controllernetwork interface devices and associated transceivers for wirelesscommunication with comparably equipped external power devices or smartcables and smart power devices using a wireless network communicationprotocol such as WiFi, WiMax, Bluetooth, or others.

In the example embodiment the power distribution and control module(200) includes a second controller network interface device (225) suchas a USB communication interface device disposed between the controllerdata processing device (220) and the device port (2) and the device port(2) includes a first SMBus configured data communication channel (248)and a second USB configured data communication channel (247) suitablyconfigured to communicate with USB configured devices operably connectedwith device port (2).

The controller memory module (230) is used to store and periodicallyrefresh state information, energy management schema information, DCnetwork configuration data, operating programs such as firmware and/orsoftware, and other digital data, including look-up tables or the likelisting power data for commonly used rechargeable DC batteries and orpower loads that is used by the controller data processing device (220)to operate the power distribution and control module (200) and to managepower exchanges with connected external power devices according topredefined operating modes.

In the present non-limiting example embodiment, each device port (1-6)can be operably disconnected from the power bus (210) or operablyconnected to the power bus (210) over a power channel such as (231, 232,233, 234, 235, 236). Generally the power bus (210) is operated at asubstantially constant bus voltage. While the bus voltage is preferablycentered at a desired DC voltage the bus voltage is variable over anoperating range depending on fluctuations in power conditions on theoverall DC power network. However in some operating modes, the busvoltage operating range may be stepped up or stepped down to improvepower distribution efficiency. See provisional U.S. Patent ApplicationSer. No. 62/077,993, filed Nov. 11, 2014, entitled Power DistributionSystem which is incorporated herein by reference in its entirety for allpurposes. However once a bus voltage operating range is established,power input to the power bus and power output from the power bus are atthe instantaneous bus operating voltage unless the input or outputvoltage is modified by a power converter or the like.

The power channels (231, 232, 233, 234, 235, 236) each comprise anelectrically conductive element such as a wire, a printed circuit boardtrace on a support substrate, or another conductive pathway that extendsfrom a single device port to the power bus. Each power channel includesan operable switch or other current modulating device operable by thecontroller data processing device (220) disposed along the power channelto operably connect the associated device port to the power bus (210) oroperably disconnect the associated device port from the power bus (210)in response to actuating the operable switch. Each power channeloptionally includes an electrical sensor (252, 254, 256, 258, 260, and262) in communication with the controller data processing device (220)and disposed between the device port and the operable switch. Theelectrical sensors are operable to sense voltage, current, and or poweramplitude and to transmit a sensor signal to the controller dataprocessing device (220). In any case each sensor communicates a sensorsignal to the controller data processing device (220) and the controllerdata processor interprets the sensor signal to determine voltage, powerand current amplitude at the sensor location.

Some of the power channels, e.g. (232, 233, 234) include an output DC toDC power converter (241), (242), (243) in communication with thecontroller data processing device (220). Each output DC to DC powerconverter is disposed along a power channel between the power bus (210)and a corresponding device port or between the power bus andcorresponding electronic sensors e.g. (254) if so equipped. Other of thepower channels may include input DC to DC power converters (244), (245),each in communication with the controller data processing device (220).Each input DC to DC power converter is disposed along a power channelbetween the power bus (210) and corresponding device ports or betweenthe power bus and corresponding electronic sensors e.g. (260) if soequipped. Each input power converter is operable by the controller dataprocessing device (220) to step up or step down a power signal voltageas needed to match an input power signal voltage to the bus voltage.Each output power converter is operable by the controller dataprocessing device (220) to step up or step down a power signal voltageas needed to match an output power signal to a voltage that iscompatible with an external power device receiving the output powersignal. Each power converter is also operable to modulate DC currentamplitude substantially between zero and the full current amplitude ofthe power signal being modulated. The level of DC current modulation iscontrolled by the controller data processing device (220) and the energymanagement schema in a manner that distributes and manages power signalsat power amplitude levels that are safe and efficient. Moreover sinceeach power converter is operable as a DC current attenuator, powerchannels that include a DC to DC power converter (241), (242), (243),(244), (245) do not require a separate operable switch operable toconnect the device port to or disconnect the device port from the powerbus (210) but a switch may be included without deviating from thepresent invention.

In an alternative non-limiting example embodiment, one device port has afirst power channel, e.g. (231) associated with port (5) that includes acontrollable switching element (240) and no power converter. In thisconfiguration port (5) is usable as an input port or an output port forexternal power devices having an operating voltage range that iscompatible with the bus voltage, e.g. to connect any external powerdevice to the power bus that can be connected to the power bus (210)without power conversion or current attenuation. In an alternativenon-limiting example embodiment, each device port has a first powerchannel that includes a controllable switching element, e.g. (240), andno DC to DC power converter such as to create a DC power network whereinall the external devices are operable at the bus voltage. In the same,non-limiting example embodiment, some or all or the device ports mayinclude a second power channel extending to the power bus wherein thesecond power channel either includes or can be routed through an inputor an output power converter as needed to make an appropriate powerconversions.

In an exemplary non-limiting operating mode, the power bus (210) isoperated at a voltage range substantially centered at 15 VDC. The outputDC to DC power converters (241), (242) and (243) are operable by thecontroller data processing device (220) to make an output voltageconversion from the power bus voltage of 15 VDC to any voltage between10 and 24 volts DC. Similarly the input DC to DC power converters (244)and (245) are operable by the controller data processing device (220) tomake an input voltage conversion from any voltage between 4 and 34 VDCto the power bus voltage of 15 VDC. In one example embodiment, aportable military radio connected to the power bus has an operatingvoltage range of 10-14 VDC, with an average idle mode power demand of 6watts with an idle current of 0.4 Amp and a peak power demand of 20watts in transmit mode with a peak current of 2 Amp.

An internal power load (285) powers elements of the power distributionand control module (200) as required. The internal power load (285) maycomprise a rechargeable battery which is charged using a portion of theinput power available from the power bus (210). The internal power load(285) comprises an internal or system power load which includes whateverpower load is demanded by the controller data processing device (220),controller memory module (230) and controller network interface devices(246) and (225) and by other devices including controllable switchingelements (240), DC to DC power converters, e.g. (241), (244), the userinterface device (270), and any other system elements that consumepower. The internal power load (285) may include a power or voltageregulator such as a linear regulator or a shunt regulator configured tocondition power signals drawn from the power bus as needed to powerelectronic control elements of the power distribution and control module(200). An operating program that includes an energy management schemaoperates on the controller data processing device (220) and controllermemory module (230).

Preferably, the power distribution and control module (200) includes auser interface device (270) in communication with the controller dataprocessing device (220). The user interface device (270) includes avideo display operable to display text and/or graphic symbols or othervisual indicators such as indicator lights or the like as well as a userinput device such as keypad elements or the like responsive to userinputs. The user interface device (270) is operable to display variousindicators related to operating parameters of the power managerincluding status, error codes, menus, or the like and to respond to userinput sections such as menu choices or the like.

7.2 Power Distribution and Control Module Having a Single Input Port

Referring now to FIG. 3 a second exemplary non-limiting DC powerdistribution and control module (300) according to the present inventionincludes an electronic control module (320) and a power distributionnetwork (315) configured to electrically interface with a plurality ofexternal power devices. In the present non-limiting exemplary embodimentthe power distribution and control module (300) is a portable DC batterycharging system suitable for scavenging DC power from an input DC powersource (340) and distributing the available DC input power to one ormore of a plurality of output DC power loads (345), e.g. rechargeable DCbatteries, connected to output device ports (310).

The power distribution and control module (300) is operable to receiveDC input power from an external DC power source (340) connected to aninput device port (305). Input DC power source (340) may provide inputpower over a range of input DC voltages, e.g. ranging between about 2 to60 VDC with an associated input current amplitude range of between about0 to 20 A providing a usable input power range of about a few microwattsto about 1.2 Kilowatts. The DC power distribution and control module(300) is further configured to include a plurality of DC to DC powerconverters (360) with one DC power converter dedicated to each outputdevice port (310). The DC to DC power converters (360) are each operableto receive a power signal at whatever input voltage is provided by theinput DC power source (340) and to convert the input voltage to anoutput voltage matched to an operating voltage of whatever DC power load(345) is being powered by the power channel associated with the DC to DCpower converter (360). Thus each DC to DC power converter (360) isoperable to convert the input voltage range of 2 to 60 VDC to an outputvoltage matched to an operating voltage of whatever external powerdevice is connected to the output device port (310) associated with thepower converter. Alternately the power distribution and control module(300) can be configured to operate with other input and output DCvoltage ranges without deviating from the present invention. A relatedpower distribution system and operating method is described in commonlyassigned U.S. Provisional Pat. No. 62/077,993, entitled POWERDISTRIBUTION SYSTEM, filed Nov. 11, 2014 by David Long which isincorporated herein by reference in its entirety for all purposes.Additionally, a related commercially available portable battery chargeris available from Protonex Technology Corporation of Southborough Mass.under the product name Advanced Battery Charger.

The power distribution and control module (300) includes an input deviceport (305) and a plurality of output device ports (310) and each deviceport is configured to electrically interface with an external powerdevice. External power devices connectable to device ports include a DCpower source (340) electrically interfaced with a single input deviceport (305). The DC power source (340) may include an electrochemicalpower generator or fuel cell, a portable mechanical power generator suchas a portable wind, wave or water turbine, a fossil fuel powered enginedriving a DC power generator or a battery powered by the DC powergenerator, an electrically powered DC power generator (e.g. a DC powerconverter connected to an AC power grid), or the like. Additionally theDC power source (340) may comprise a smart rechargeable DC battery orpower load that includes a smart rechargeable DC battery.

The external power devices include a plurality of DC power loads (345)connected to one or more output device ports (310). The DC power loads(345) may comprise one or more smart rechargeable DC batteries connectedto the power distribution and control module (300) for recharging. Inone non-limiting exemplary embodiment some or all of the smartrechargeable DC batteries are standalone devices not associated with apower load. In other non-limiting exemplary embodiments some or all ofthe smart rechargeable DC batteries are interfaced with a power loadwhich may be operating or idle while the smart rechargeable battery isconnected to the output device port (310).

Generally a power load consumes electrical power to perform a task.Typically each DC power load (345) that is not a standalone smartrechargeable DC battery includes its own rechargeable DC batteryassociated therewith, often mounted inside a housing of the DC powerload (345). Preferably the rechargeable DC battery is a smart batterythat includes a digital communication interface, e.g. a battery networkinterface device and at least a programmable, non-volatile batterymemory module provided on the smart battery to store digital informationrelated to the battery itself and or to the load being powered by thebattery. Typically the stored digital information includes powercharacteristics of the power load and power characteristics of therechargeable DC battery in a format that is readable by the powerdistribution and control module (300). DC power loads (345) may includewireless communications devices, portable computers, navigation devices,DC lighting, power tools, heaters, food preparation devices, motors,fans, or the like such as may be encountered in a DC powered vehicle orother DC powered system.

When the power distribution and control module (300) is used to rechargea standalone rechargeable DC battery, substantially all power deliveredto the standalone DC battery by the power distribution and controlmodule (300) is stored by the battery. When a DC power load (345) isinterfaced with a smart DC rechargeable battery connected to an outputdevice port (310) and the power load is not operating, e.g. the powerload is turned off or in idle mode, the battery management module of thepresent invention may treat such a smart DC battery as a standalonebattery instead of a power load.

In one example use scenario, a reliable DC power source becomesavailable and the user or users connect a plurality of rechargeable DCbatteries to output device ports (310) of the power distribution andcontrol module (300) for rapid recharging. If the rechargeable DCbatteries are associated with a power load, the power load may be set ina non-operating mode (e.g. by a user) in order to ensure that therechargeable battery will be fully charged. Thus depending on userselectable configurations and operating modes of DC power loads (345),each DC power load (345) connected to an output device port (310) can becharacterized as a power load or as a standalone rechargeable DC batteryand the battery management module of the present inventions is operabletreat these two cases differently.

The input device port (305) and plurality of output device ports (310)are each formed by an electrical power connector supported by a housingwall, or the like, of an electronic enclosure, not shown. Preferablyeach power connector includes a power channel and a communicationchannel, although in some embodiments the communication channel maycomprise a wireless communication network wherein external power devicesare operating as nodes on the wireless network. In some embodiments, thecommunication channel and power channel is the same channel withcommunication signals transmitted over the power channel. Generally asingle power channel comprises two wires or two conductive conduits,e.g. one connected to a positive power terminal and the other connectedto a negative power terminal. Similarly a single communication channelmay comprise a wire pair (two wires).

Each external power device e.g. DC power source (340) and output DCpower load (345) connects to the device port connector using a wireconnector or adaptor disposed between the device port and the externalpower device. The wire connector or adaptor includes an electrical powerconnector, or the like, at each end thereof. One end of the wireconnector or adaptor is electrically interfaced with the device port andthe other end of the wire connector or adaptor is electricallyinterfaced with the external power device as further detailed below andshown in FIG. 4.

The mating electrical power connector may be associated with a wirecable, a power adaptor, or may be incorporated into the external powerdevice. If a wire cable or a power adaptor is used, the wire cable oradaptor extends between an input device port (305) or output device port(310) and the external power device. The external power devices mayinclude an input output (I/O) port suitably formed to interface with theelectrical power connector provided by the wire cable or adaptor.Preferably the external power device I/O port and the wire cable oradaptor includes a power channel and a communications channel.

The power distribution and control module (300) includes a powerdistribution network (315) electrically interconnecting the input deviceport (305) with each of the plurality of output device ports (310). Thepower distribution network (315) comprises a plurality of conductivepathways such as may be formed by individual wires or branchedconductive pathways such as traces formed on a printed circuit board, orthe like. Each conductive pathway extends from the input device port toone of the output device ports but a portion of the conductive pathwayproximate to the input device port may be shared by all of the pluralityof conductive pathways. In the present example the power distributionnetwork (315) connects each output device port (310) to the input deviceport (305) over a different DC to DC power converter (360).

The power distribution network (315) includes a plurality ofunidirectional DC to DC power converters (360) with one DC to DC powerconverter (360) associated with each output device port (310). Each DCto DC power converter (360) includes an input terminal (365) which is inelectrical communication with the input device port (305) over the powerdistribution network (315). Thus the voltage of the input power signalat each of the DC to DC power converter input terminals (365) is alwayssubstantially equal to the instantaneous voltage of the DC power source(340) connected to the input device port (305).

Each of the plurality of DC to DC power converters (360) includes anoutput terminal (370). Each output terminal (370) is connected to adifferent one of the plurality of output device ports (310). Thus eachoutput device port (310) is associated with a dedicated DC to DC powerconverter (360) operable to convert the DC voltage present at the inputterminal (365) to a DC voltage that is matched to an operating voltagerange of whatever DC power load (345) is electrically interfaced withthe output device port (310) associated with the DC to DC powerconverter (360). The DC to DC voltage conversion may step up (increase)the input voltage, or step down (decrease) the input voltage, dependingon which is needed to match an operating voltage range of a DC powerload (345) interfaced with the corresponding output device port (310).The controller data processing device (325) manages voltage conversionsetting of each of the DC to DC power converters (360) by continuouslyadjusting the conversion settings to convert instantaneous input voltageat input terminals (365) to desired output voltages at each outputdevice port (310).

Preferably each DC to DC power converter (360) is further operable tomodulate current amplitude of a power signal passing there through.Preferably the current amplitude can be modulated substantiallycontinuously between 0 and 100% of the input current amplitude at inputterminal (365); however current amplitude can be modulatednon-continuously using discrete current amplitude steps between 0 and100% of the input current amplitude without deviating from the presentinvention. Additionally each DC to DC power converter (360) can beoperated to modulate current amplitude even when no voltage conversionis required. Thus each DC to DC power converter (360) is operable as aswitch when the DC to DC power converter (360) is configured toattenuate current amplitude to substantially zero current amplitude inorder to substantially disconnect the associated output device port(310) from the power distribution network (315). Additionally dependingon how the DC to DC power converter is controlled each of the DC to DCpower converters (360) is operable as a current or a power limiter tolimit either current amplitude or power amplitude to a preset maximumand or to limit current or power amplitude to a preset range byestablishing maximum and minimum current amplitude limits.

Optionally each branch of the power distribution network (315) mayinclude a controllable switch (390) provided in addition to the DC to DCpower converter (360) on the same branch. The controllable switch (390)is in communication with and controlled by the controller dataprocessing device (325) and is disposed along any branch of the powerdistribution network (315) that leads to an output device port (310).Each controllable switch (390) is controllable to selectively disconnectand reconnect a single output device port (310) from the powerdistribution network (315). In various embodiments the controllableswitch (390) is disposed between the input port (305) and the DC to DCconverter input terminal (365) or between the DC to DC converter outputterminal (370) and the output power sensor (355).

The power distribution and control module (300) includes an electroniccontrol module (320). The electronic control module includes acontroller data processing device (325), a controller memory module(330) in communication with the controller data processing device (325)and a controller network interface device (335) also in communicationwith the controller data processing device (325). The controller memorymodule and or controller digital communication device interface can beincorporated within the controller data processing device (325).

An internal power load (385) powers elements of the electronic controlmodule (320) and other electronic control elements of the powerdistribution and control module (300) as required. The internal powerload (385) may comprise a rechargeable battery which is charged using aportion of the input power received through the input device port (305).Otherwise the internal power load (385) comprises an internal or systempower load powered by a portion of the input power received through theinput port. The internal power load (385) may include a power or voltageregulator such as a linear regulator or a shunt regulator configured tocondition power signals as needed to power electronic control elementsof the power distribution and control module (300). An operating programthat includes an energy management schema operates on the controllerdata processing device (325) and controller memory module (330). Theoperating program and energy management schema manage communication withconnected external power devices as well as manage operating modes ofactive control elements such as the DC to DC power converters (360), anycontrollable switches (390), and passive elements including input powersensor (350), output power sensors (355), the internal power load (385)and the controller memory (330) to distribute input power to selectedpower loads. In addition the energy management schema includes a batterymanager module operable to charge standalone smart DC batteriesconnected to any of the output device ports (310).

A communication channel (375) shown as dashed lines, extends from thecontroller network interface device (335) to each of the device portsand is operable to exchange digital, e.g. packet based, communicationsignals between the controller data processing device (325) and eachexternal power device operably connected to an input device port (305)or an output device port (310). In a preferred embodiment thecommunication channel (375) is a SMbus network typically used tocommunicate with smart batteries and other external power devices and orelectronic control elements. Alternately or additionally the powerdistribution and control module (300) can use other or additionalcontroller network interface devices (335) operating with differentnetwork protocols without deviating from the present invention. Someexample other communication protocols include the Inter-IntegratedNetwork (IIC) communication protocol, the Universal Serial Bus (USB)communication protocol, the IEEE 802.15.1 Blue Tooth communicationprotocol, the IEEE 802.3 Ethernet communication protocol, the IEEE802.11 WiFi communication protocol, the IEEE 802.16 WiMax communicationprotocol, one of the IEEE 802.20 Mobile Broadband Wireless Accesscommunication protocols, which includes cellular radio network datacommunications, or one or more serial or parallel communications deviceprotocol such as RS-232 or RS485, the internet protocol or other datacommunication protocols that permit bi-directional (full-duplex orhalf-duplex) data transfer.

Other electronic control elements of the power distribution and controlmodule (300) are in communication with the electronic control module(320) and controlled by the controller data processing device (325)operating program and energy management schema. These include the DC toDC power converters (360), input power sensors (350), output powersensors (355), controllable switches (390), temperature sensors, (notshown) or the like, operating in cooperation with the electronic controlmodule (320). While communication between the other electronic controlelements and the controller data processing device (325) may be over thecommunications channel (375), a separate electrical communication forinternal devices is used for digital and or analog signal exchangebetween the controller data processing device (325) and any otherelectric elements associated with the power distribution and controlmodule (300).

An input power sensor (350) in communication with the controller dataprocessing device (325) is provided to sense substantially instantaneousinput voltage and input power or current amplitude proximate to theinput device port (305). The input power sensor (350) transmits an inputpower signal to the controller data processing device (325) whichinterprets the input power signal as instantaneous voltage and poweramplitude each of which is used to configure the power distributioncontrol module (300) to distribute the instantaneous input poweramplitude according to polices of the energy management schema.

A plurality of output power sensors (355) each in communication with thecontroller data processing device (325) is provided with one outputpower sensor (355) associated with each output device port (310) tosense substantially instantaneous output voltage and output poweramplitude proximate to each of the output device ports (310). The outputpower sensors (355) each transmit an output power signal to thecontroller data processing device (325) which interprets each outputpower signal as instantaneous voltage and power amplitude. The outputpower signals are each used to configure and reconfigure the DC to DCpower converters (360) and other elements of the DC power network tomanage the instantaneous output power amplitude at each output deviceport (310) according to polices of the energy management schema. Theinput power sensor (350) and each output power sensor (355) comprise anysensor or module that is operable to determine any two of instantaneousvoltage, instantaneous current amplitude, and instantaneous poweramplitude.

The power distribution and control module (300) includes a userinterface device (395) in communication with the controller dataprocessing device (325). The user interface device (395) may include avideo display operable to display text and/or graphic symbols or othervisual indicators such as indicator lights or the like as well as a userinput device such as keypad elements or the like responsive to userinputs. The user interface device (395) is operable to display variousindicators related to operating parameters of the power managerincluding status, error codes, menus or the like and to respond to userinput sections such as menu choices or the like.

7.2.1 Operating Mode

A basic non-limiting exemplary operating mode of each of the powerdistribution and control modules (200) and (300) described above is asfollows. The energy management schema maps the DC power network bypolling each device port using a digital communication signaltransmitted over a controller network interface device (246) (335) andassociated controller communication channels (247), (248), (375). Thepolling query is directed to external power devices connected to deviceports. If an external power device does not respond to the pollingquery, the device ports where no response is received are inactivated.Inactivation is accomplished by operating a controllable switchingelement, e.g. (240) in FIG. 2, or operating a controllable DC to DCpower converter, e.g. the DC to DC power converters (241) associatedwith output devices shown in FIG. 2 or DC to DC power converters (360)associated with output devices in FIG. 3 as a controllable switch todisconnect the device port from the power bus (210) in FIG. 2, or todisconnect output device ports (310) of the power distribution network(315) in FIG. 3.

The polling query includes a request for information. The requestedinformation includes one or more of: device ID, device type ID,operating voltage range, peak, average and idle mode operating powerrequirements, including input power for power sources or output powerfor power loads or standalone rechargeable batteries. Additionalinformation may further be requested or provided including operatingcurrent ranges and other parameters that may be available. If aconnected external power device is a smart rechargeable battery thepolling query may request a battery capacity e.g. measured in watt-hours(Wh) or ampere-hours (Ahr), State of Charge (SoC), Time to Empty (TtE)or related metric indicative of what portion of the battery capacity isstill usable or how much longer the battery can be used before itspresent charge capacity is used up. Additionally a smart rechargeablebattery may provide charging information such as charging currentamplitude ranges and temporal current amplitude profiles, or the like.If the requested information is provided, the energy management schemauses the requested information to map the DC power network to store therequested information in tables associated with the correspondingdevices and establish operating parameters suitable to distribute theavailable input power to one or more power loads and or standalonerechargeable DC batteries connected to output ports. The polling queryis repeated at a constant polling rate such as every 20 to 100 msec;however any polling rate that provides acceptable network performance isusable.

Some external power devices can be dumb devices, meaning they cannotrespond to a polling query or they can respond to the polling query butonly with limited information, such only with a device ID and devicetype ID, or with less than all the information needed by the energymanagement schema to configure the DC power network. To support dumbexternal power devices, the power distribution and control module (200)(300) is operable to store device type profiles on the controller memorymodule (230), (330) or controller data processing device (220) (325) andto look up a device type ID profile to determine power characteristicsassociated a dumb device of a particular device type connected to thepower distribution and control module (200) (300). Specifically thecontroller memory module (230), (330) store look up tables and or thelike that contain power characteristic information for various DC powerloads, DC power sources and rechargeable DC batteries that arecompatible the power distribution and control module (200) (300).

Thus, when desired information is not provided or only limited powerinformation is obtainable by communication with an external powerdevice, the energy management schema operates to use what information isavailable to look up power characteristic information in look up tablesstored on the controller memory module (230) (330) to determine if theconnected device is operable on the DC power network and if so usingwhat power parameters. If the connected power device cannot beidentified, it is either never connected or if already connected; it isdisconnected from the power bus or power distribution network.

The energy management schema is further operable to store historic datacollected from external power devices connected to external device portson the controller memory module (230), (330) and the historic data isretrieved as needed when the same or a similar external power device isconnected to a device port. In other embodiments described below, dumbdevices can be associated with smart wire cables and or smart adaptorsconfigured to include data storage and data communication elementsoperable on the cables or smart adaptors to communicate with thecontroller data processor and controller memory devices operating on thepower distribution and control modules (200) and (300).

8 EXTERNAL POWER DEVICE CONFIGURATIONS

Turning now to FIG. 4 a schematic diagram depicts power andcommunication elements associated with a device port (405) operating ona power distribution and control module (400) according to the presentinvention. The power distribution and control module (400) is either ofthe power and distribution and control modules (200) or (300) describedabove. An external power device (410) is electrically interfaced to thedevice port (405) over a smart wire cable or smart adaptor (415). Thesmart wire cable or smart adaptor (415) preferably includes electricalpower connectors (402) and (404) formed at each of two opposing ends ofa power conductor or power channel (421) such as a wire or otherconductive element. The electrical power connector (402) interfaces withthe device port (405) and the electrical connector (404) interfaces withthe external power device (410), e.g. at an I/O port (406). A smartadaptor (415), that does not necessarily include a wire cable butinstead may comprise a conductive trace mounted on a substrate, or thelike, provides an alternate electrical interface to a wire connectorwherein mechanical structure of the smart adaptor supports electricalpower connectors (402) and (404) in a manner that provides the desiredelectrical interface between the external power device (410) and thedevice port (405). The smart wire cable or adaptor (415) may comprise aportion of either of the external power device (410) or the powerdistribution and control module (400) such as when the smart wire cableor adaptor (415) is partially or entirely formed by the enclosure of thepower distribution and control module (400) or by an enclosure of theexternal power device (410), or the smart wire cable or adaptor (415)may comprise a standalone element. It is further noted that either endof the smart wire cable or smart adaptor (415) may be substantiallypermanently tethered to either one of the device port (405) or the I/Oport (406) without deviating from the present invention.

A communication channel (408) extends from a controller networkinterface device (425) provided on the power distribution and controlmodule (400), through the device port (405) and the communicationchannel (408) continues either to the external power device (410)through the I/O port (406), if the external power device is configuredas a smart device, or may terminate in the smart wire cable or smartadaptor (415) if the smart wire cable or smart adaptor is configured asa smart device. In the case where the external power device (410) isconfigured as a smart device, a smart cable or smart adaptor is notrequired. However a dumb cable is used instead wherein the dumb cablecomprises an electrical cable with electrical terminals or connectorsprovided on each end thereof.

A power sensor (440) in communication with a controller data processingdevice (430) is operable to sense instantaneous voltage and power orcurrent amplitude passing over the device port (405). Preferably thepower sensor (440) senses instantaneous voltage and power amplitude forbidirectional input power and output power. Ideally the power sensor(440) is operable to sense instantaneous voltage at the device port(405) and other parameters that allow the data processing device (430)to determine instantaneous power or current. In some operating modes,the power sensor (440) is usable to sense voltage and power amplitudebeing drawn by a dumb power load so that the load can be powered.Alternately the power sensor (440) is usable to sense voltage and poweramplitude available from a dumb power source so that the source can beused to power other devices.

The power distribution and control module (400) includes a controllableswitching element (445) disposed along a power channel (420). Thecontrollable switching element is operable by the controller dataprocessing device (430) to disconnect and reconnect the device port(405) from the power channel (420). As noted above, the controllableswitching element (445) comprises either a controllable switch (445) ora DC to DC power converter (446) operable to modulate current amplitude,or both.

8.1 Smart External Power Device

The external power device (410) is depicted as a smart device thatincludes a smart rechargeable DC battery (412) and a DC power load (465)being powered by the smart rechargeable DC battery (412). The smartrechargeable DC battery (412) comprises chemical energy storage device(470), a battery digital data processor (450), a battery memory (455),in communication with the battery data processor (450), and a batterynetwork interface device (460) in communication with the battery dataprocessor (450). The smart battery further includes a first I/O port(406) for electrically interfacing with the power distribution andcontrol module (400) and a second I/O port (407) for interfacing withthe power load (465). An input power channel (475) extends between abattery I/O port (406) and the chemical energy storage device (470) andan output power channel (476) extending between the chemical energystorage device (470) and the DC power load (465). The skilled artisanwill recognize that the power load (465) has two power terminals, e.g.positive and negative power terminals, with one power terminal, e.g. thepositive power terminal, connected with the power bus or other positivepower terminal associated of the power distribution and control module(400) and the negative power terminal connected with a negative orground terminal of the power distribution and control module (400).Accordingly each leg of the power channel (476), (475), (420) comprisesa wire pair with one wire connecting positive power terminals in seriesand the other wire connecting negative power terminals in series.

Other configurations are possible, e.g. the battery data processor (450)is optional, since in some cases the battery memory (455) can be read bythe controller data processing device (430) without a battery dataprocessor (450). Additionally the battery digital data processor (450),the battery memory (455), and the battery network interface device (460)may be combined on the same device such as the data processor. In anyevent, any smart device configured to exchange communication signalswith the controller data processing device (430) is usable withoutdeviating from the present invention. Moreover as noted above when theexternal power device is a smart device, the smart cable or adaptor(415) can be replaced by a dumb cable or adaptor that simply provides apower channel (421) and connectors (404) and (420) and a communicationchannel (408) operable to electrically interface with communicationchannel terminals at each of the device port (406) and the I/O port(405).

The DC power load (465) draws power from the chemical energy storagedevice (470). While the DC power load (465) may communicate with thebattery digital processor (450) to track state of charge (SoC) time toempty (TtE), or the like, the DC power load (465) is not necessarily incommunication with the power distribution and control module (400).Typically, the DC power load (465) and the smart rechargeable DC battery(412) are packaged together as a portable device that can bedisconnected from device port (405) and operated independently of the DCpower distribution and control module (400). In a typical scenario, theonly communication between the smart external power device (410) and theDC power distribution and control module (400) is by the smartrechargeable DC battery (412) and then only when the smart rechargeableDC battery (412) is interfaced with a device port (405). As a result,the DC power distribution and control module (400) is often only awareof the State of Charge and charge storage capacity of the battery andhas no access to information about the power load (465) such as itsactual power consumption over time.

The external power device (410) may comprise a standalone smartrechargeable DC battery (412). This may be the case when a smartrechargeable DC battery (412) is removed from or otherwise separatedfrom the DC power load (465) and only the smart rechargeable DC batteryis connected to the device port (405) for recharging or to be used as apower source. Alternately a smart rechargeable DC battery (412) mayoperate like a standalone smart rechargeable battery even when connectedto the DC power load (465), which may be the case when the power load isturned off or placed in an idle mode by a user.

In the case of the power distribution and control module (300) which isprimarily configured to recharge smart batteries, the typicalconfiguration is that all of the output device ports are each connectedto a standalone smart battery and the control module is operated torecharge the connected smart batteries as standalone devices. Exemplarysmart batteries usable with the present invention include but are notlimited to military batteries e.g. models BB-390, BB-2001, BB-2590,BB-2600, BB-2800, BB-2847, PRC-148, PRC-152, PRC-153 and the ConformableWearable Battery (CWB).

The device port (405) is operable as either an input or an output deviceport where the power distribution and control module configurationallows it. In an exemplary operating mode of the present invention,smart rechargeable DC batteries (412) that include a DC power load (465)are treated as power loads. Smart rechargeable DC batteries (412) thatdo not include a DC power load (465) or wherein the power load is turnedoff or in idle mode are treated as a standalone rechargeable battery. Inone operating mode each standalone rechargeable battery connected to thepower distribution and control module (200) or (300) is allocatedcharging power when sufficient input power is available. In oneoperating mode one or more standalone rechargeable batteries are used asan input power source when insufficient input power prevents poweringhigh priority power loads connected to the power distribution andcontrol module (400).

8.1.1 Power Exchanges with Smart Devices

While a smart rechargeable DC battery (412) is connected to a deviceport (405) the battery digital data processor (450) and the controllerdata processing device (430) operating on power distribution and controlmodule (400) are in communication over the communication channel (408)through the controller network interface device (425) and batterynetwork interface device (460). In cases where a smart rechargeable DCbattery (412) is connected to a device port (405) the smart cable oradaptor element (415) is not required and simple cable connector withelectrical connectors at each end is used. In response to queries fromthe controller data processing device (430) the battery digital dataprocessor (450) reports data such as a device ID, a device type, anoperating voltage range, current amplitude limits, peak and averagepower requirements, battery capacity e.g. measured in watt-hours (Wh) orampere-hours (Ahr), SoC or TtE, or related metric indicative of whatportion of the battery capacity is still usable or how much longer thebattery can be used before its present charge capacity is used up,charging information such as fully charged voltage, fully dischargedvoltage, or the like. Alternately when only a device type is reported,the remaining information may be pulled from look-up tables, or thelike, stored on the controller memory (435) or data processing device(430). The power requirements reported by the smart battery associatedwith a power load may be associated only with the DC power load (465)only with the DC battery, or both; however, when no load is present orthe load is not operating the power requirements only relate to thesmart rechargeable DC battery (412).

Once the device type and power characteristics of the external powerdevice (410) are known, the energy management schema operates todetermine if a voltage conversion is needed and if so, whether a DC toDC power converter (446) is available and can be configured for therequired voltage conversion. If a suitable power configuration isavailable, the DC to DC power converter (446) is configured for thedesired voltage conversion. Additionally the DC to DC power converter(446) is optionally configured to provide current amplitude and or poweramplitude limits. Once configured the energy management schema furtherconfigures the power distribution and control module (400) to powerexternal power device (410) using input power available from a connectedpower source or sources. Thereafter the energy management schemaperiodically queries the external power device (410) to determine if thedevice (410) is still connected to the device port and to refresh powercharacteristic data e.g. SoC.

8.1.2 Smart Cable Adaptor

In some situations it is desirable to connect a dumb DC power load (465)or dumb battery to the device port (405). In such cases a smart wirecable or smart adaptor (415) is disposed between the dumb device, e.g.the DC power load (465), and the device port (405) and the smart wirecable or smart adaptor (415) is configured to store and exchange digitaldata with the controller data processing device (430) over thecommunication channel (408). The smart wire cable or smart adaptor (415)is configured with a cable data processing device (450 a), a cablememory module (455 a) in communication with the cable data processingdevice (450 a) and a cable network interface device (460 a) interfacedto the communication channel (408). The smart wire cable or smartadaptor (415) is configured to store power characteristics of theassociated DC power load (465) on the cable memory module (455 a) and orcable data processing device (450 a) which are operable to respond toqueries from the controller data processing device (430) and to providesome or all of the stored data to the controller data processing device(430). At a minimum, a device ID and device type are stored on the smartwire cable or smart adaptor (415); however, other power characteristicssuch as operating voltage range, peak and average power consumption, andcurrent limits can also be stored on the smart wire cable or smartadaptor (415). Once power characteristics stored on the smart wire cableor smart adaptor (415) are read by the controller data processing device(430) the energy management schema is operable to look up additionalpower characteristics corresponding to the device type and thenconfigure the power network to add the dumb DC power load (465) to a DCpower network as described above.

In another example configuration a rechargeable dumb battery or aplurality of rechargeable dumb batteries is associated with a smart wirecable or smart adaptor (415) and connected to the device port (405). Inthis case the smart wire cable or smart adaptor (415) is configured toinclude power information associated with the dumb rechargeable batteryor batteries stored thereon in a format readable by the controller dataprocessing device (430). Once included in the DC power networkestablished by the energy management schema the rechargeable dumbbatteries may be recharged by a battery management module operating onthe energy management schema or may be treated as a DC power supplyusable to deliver input power to the DC power network to power loadsconnected to the power distribution and control module (400).

Other smart cable/adaptor configurations are possible, e.g. the cabledata processing device (450 a) is optional, since the cable memorymodule (455 a) can be read by the controller data processing device(430) without a cable data processor (450 a). Additionally the cabledata processing device (450 a), the cable memory module (455 a), and thecable network interface device (460 a) may be combined on the samedevice. In any event, any smart cable or smart adaptor configured toexchange communication signals with the controller data processingdevice (430) is usable without deviating from the present invention.

In other situations where it may be desirable to connect the DC powerload (465) directly to the device port (405) without the smartrechargeable DC battery (412) and without a smart cable or adaptor orwhen the smart cable or adaptor does not have the power characteristicsof the connected DC power load (465) a sensor signal output from thepower sensor (440) may be usable to determine power characteristics ofthe connected DC power load (465). For example, an operating voltage andinstantaneous power draw may be sensed by the power sensor (440) when atest current is delivered to the connected dumb DC power load (465) inorder to determine its power characteristics. In particular a resistorof known resistance, or the like, associated with the power sensor (440)may be used to determine a voltage and or current amplitude of anincoming or outgoing power signal passing over the resistor.

8.2 Allocating Power to DC Power Loads

Referring to FIGS. 1-5 a DC power load (465) is any electrical devicethat consumes DC electrical power to perform a task. Conversely, while astandalone rechargeable DC battery receives DC power during recharging,substantially all of the DC power received by the standalonerechargeable DC battery is stored thereby and is potentially retrievableexcluding losses due to power conversions and other inefficiencies.Moreover the energy stored by standalone rechargeable DC batteries isretrievable by the power distribution and control networks describedherein. In the first non-limiting example embodiment of FIG. 2, asoldier power manager (110) and DC power loads (130, 140, 150, 160) areelectronic devices carried by an infantry soldier and most if not all ofthe DC power loads include a smart rechargeable DC battery (412) orother rechargeable battery associated with a smart wire cable or smartadaptor (415), shown in FIG. 4.

Thus typical external DC power loads operable with the present inventioninclude a DC power load and an associated rechargeable DC battery orother energy storage device connected by a smart cable. The DC powerloads vary with respect to power consumption or power allocation needs,with some DC power loads having a substantially constant powerallocation requirement, e.g. a lamp, a fan or pump operating at constantspeed, while other DC power loads have time varying power demands as maybe the case for a communication device which demands a peak DC powerload to transmit and a lower DC power load to listen. Similarly,different rechargeable DC battery types may draw different power loadsand have different operating voltage ranges during charging depending onbattery chemistry, cell configuration, energy storage capacity (e.g.measured in watt-hours (Wh) or ampere-hours (Ahr)), charging rates, andthe like, and these factors are taken into account by the energymanagement schema when allocating charging power according to thepresent invention.

Referring to FIG. 5, a flow diagram (500) provides an exemplary powerallocation process carried out by the energy management schema of thepresent invention while operating on the controller data processingdevice (220) or (325) described above. In step (505) the energymanagement schema maps the power distribution and control module (200),(300) by polling each device port to identify each external power deviceconnected thereto. The energy management schema groups connectedexternal power devices by device type according to DC power sources, DCpower loads, and standalone rechargeable DC batteries. Other devicetypes such as non-rechargeable batteries may be grouped separately ordesignated DC power sources. Additionally the energy management schemamaps each system or internal power loads (285) and (385), operable topower the power distribution and control module (200), (300) and thesystem or internal power loads are included in the total instantaneouspower demand associated with the mapped power distribution and controlmodule.

In step (510) the energy management schema determines the totalinstantaneous input power available from all the DC power sourcesconnected to the power distribution and control module and the totalinstantaneous power demand associated with all the DC power loads,including system of internal power loads. Generally the energymanagement schema does not include standalone smart rechargeable DCbatteries in the total instantaneous power load, instead only includingDC power loads. In the case of the power distribution and control module(300), which has only one input port, the only DC power source availableis connected to the input device port (305).

The total instantaneous input power may be determined based oninstantaneous input power sensor signals or may be based on powercharacteristics read from smart DC power supplies or read from smartcables/adaptors associated with DC power supplies, or both. The totalinstantaneous power demand may be determined based on instantaneousoutput power sensor signals or may be based on power characteristicsread from smart DC power loads and or read from smart cables/adaptorsassociated with DC power loads, or both. In a default operating mode,the energy management schema bases total instantaneous power demand onthe peak power demand of each DC power load. More specifically, when thepeak power demand of each DC power load is known, each DC power load isallocated a power allotment equal to its rated or expected peak powerdemand.

In step (515) the energy management schema ranks each DC power sourceaccording to its source priority and ranks each DC power load accordingto its load priority. In one non-limiting exemplary embodiment a highpower source priority is assigned to substantially unlimited DC powersources that are able to deliver substantially constant input poweramplitude at substantially constant voltage as is the case with a DCpower converter connected to an AC power grid, or the like. A highsource priority may also be assigned to an electrochemical powergenerator such as a fuel cell or an electromechanical power generatorsuch as an electrical power generator driven by a fossil fuel engine, orthe like, because the input power generated by these devices issubstantially non-time varying and the input voltage remainssubstantially constant. A lower source priority is assigned totime-varying power amplitude and or time-varying voltage power sourcessuch as a photovoltaic or wind powered energy source which generallydelivers time-varying input power amplitude at a time-varying inputvoltage due to temporal variations in wind and sunlight conditions. Aneven lower source priority is assigned to DC energy storage devices,such as rechargeable or non-rechargeable DC batteries connected to thepower distribution and control module (200), (300), which can be usedwhen no other external power sources are available but which arepreferably not used except to power high priority power loads.

In the case of the power distribution and control module (300) describedabove, only one DC power source (340) is connected to the input port(305) so a source priority is not relevant to selection which DC powersource is used to power loads. However, even when only one DC powersource is connected to either of the power distribution and controlmodules (200), (300), the source priority of the input power source maybe used by the energy management schema in determining how the totalavailable input power is distributed to power loads.

In the case of the power distribution and control module (200) two ormore DC power sources, e.g. connected to ports (3), (4) or (5), may beavailable to the power bus (210) so in the embodiment of FIG. 2 theenergy management schema is operable to connect a single DC powersource, e.g. the highest source priority DC power source, to the powerbus (210) and to base the total instantaneous input power on only onepower source while disconnecting other power sources from the power busto hold in reserve. However, if the total instantaneous input power fromone power source does not meet the total instantaneous power demand, theenergy management schema is operable to connect a plurality of inputpower sources to the power bus (210) in order to meet the totalinstantaneous power demand.

In step (520) the energy management schema allocates the totalinstantaneous input power to DC power loads connected to the powerdistribution and control module and to system or internal power loads.In a default operating mode, the energy management schema allocates thetotal available instantaneous input power to the highest priority powerloads first and then to lower priority power loads until either all ofthe connected DC power loads are powered with enough power to meet thepeak power demand of each DC power load, or until all of the totalavailable input power is allocated. The energy management schema usesthe following power allocation policies or guidelines. Each DC powerload is allocated its peak power demand, if known, whether or not thepower load is drawing peak power at the time. A DC power load will notbe allocated power unless its peak power demand can be allocated. Insome operating mode embodiments, external DC power loads that are notallocated power may be disconnected from the power distribution andcontrol module e.g. by actuating a switch (240) or attenuating currentamplitude using a DC to DC power converter, (241) as described above. Athird guideline is that standalone rechargeable batteries are notallocated charging power during the initial power allocation step (520).

8.3 Battery Charging Manager

The energy management schema of the present invention further includes abattery charging manager module operating thereon or operatingseparately on the controller data processing device (220) and (325).Since most rechargeable batteries can be recharged using low currentamplitude, e.g. trickle charging, the battery manager module of thepresent invention is operable to allocate low power amplitude signals torechargeable DC batteries connected to the DC power networks. Incontrast to DC power loads, wherein the energy management schema eitherallocates peak power to each DC power load or allocates no power to theDC power load, the battery charging manager module is operable toallocate low amplitude power signals to rechargeable batteries toincrease their state of charge using whatever unallocated input power isremaining after the available instantaneous input power has beenallocated to power loads. More specifically, the battery manager moduleallocates Total Charging Power (TCP) to one or more rechargeable DCbatteries operably connected to the power distribution and controlmodule, wherein the TCP is equal to the difference between the totalinstantaneous input power available and the total DC power allocated topower loads by step (520). In addition as will be further describedbelow, the controller data processing device (220) and (325) optionallyincludes a Peak Power Tracking (PPT) module (397) operable thereon toactively maximize input power amplitude. The PPT module (397) ispreferably operated when the input power signal is widely variable suchas when the input power is generated by a wind, solar, water driven orother power generating source that varies according to changes in localconditions or operating modes. Operation of the PPT module (397) can beuser selected or automated.

In a first non-limiting exemplary operating mode the battery managermodule allocates a portion of the TCP to each rechargeable DC batteryconnected to the power distribution and control module. In a secondnon-limiting operating mode the battery manager module allocates the TCPto selected rechargeable DC batteries connected to the powerdistribution and control module. In either operating mode the batterymanager module is operable to allocate equal portions of the TCP to eachrechargeable DC battery connected to the power distribution and controlmodule or to allocate unequal portions of the TCP to all or selectedrechargeable DC batteries connected to the power distribution andcontrol module. More generally, the battery manager module allocates theTCP to recharge smart rechargeable DC batteries connected to the powerdistribution in a manner that manages the Average State of Charge (ASoC)of a group of rechargeable DC batteries connected to the powerdistribution and control module, where the group of rechargeable DCbatteries may include all rechargeable DC batteries, only standalonerechargeable DC batteries, or another group as may be defined bypolicies operating on the battery charging manager.

As described above, the energy management schema determines the totalinstantaneous input power available and then allocates the totalinstantaneous input power to DC power loads connected to the powerdistribution and control module. In cases where the total instantaneousinput power available exceeds the total instantaneous power load, thebattery charging manager operates to allocate the TCP to one or morerechargeable DC batteries. In cases where the total instantaneous inputpower available fails to meet the total instantaneous power load, thebattery charging manager operates to allocate a portion of the totalinstantaneous input power available to the highest priority power loadsin peak power allotments to as many power loads as can be powered atpeak power. In cases where unallocated instantaneous input is remaining,i.e. when TCP is non-zero, the battery charging manager operates toallocate the TCP to one or more rechargeable DC batteries connected tothe power distribution and control module.

Referring now to FIG. 6, a schematic flow diagram (600) detailsoperating steps carried out by the battery charging manager program orschema operating on the controller data processors described aboveaccording to the present invention. As detailed above the batterycharging manager may comprise a program module of the energy managementschema or may comprise a separate program module operating on thecontroller data processor.

In a step (605) the energy management schema determines the TotalCharging Power (TCP) which is determined by subtracting the totalinstantaneous power allocated to power loads from the total availableinstantaneous input power. More specifically, the TCP is equal tounallocated instantaneous input power after the total available inputpower has been allocated to power loads by the energy management schema.

In step (610) the battery charging manager determines the instantaneousSoC of a group of rechargeable DC batteries connected to the DC powernetwork. The group may comprise all the rechargeable DC batteries,including those associated with power loads, or the group may includeonly standalone rechargeable DC batteries or combinations of bothdepending on policies operating on the battery charging manager. Theinstantaneous SoC information is refreshed each time the energymanagement schema maps the power distribution and control module in step(505), described above, and the SoC values are stored on the controllermemory module (230) or (330) e.g. in tables associated with connectedexternal DC power devices, or the like.

The SoC may be read from smart rechargeable DC batteries or may beinferred from power sensor signals e.g. by estimating the SoC based onthe instantaneous operating voltage of the rechargeable DC battery ascompared to characteristics of the battery type such as the fullycharged and fully discharged voltages. In one example wherein aparticular battery type has a fully charged voltage of 12.2 volts and afully discharged voltage of 9.8 volts, an instantaneous battery voltageof 11 volts suggests that battery SoC is 50%.

In addition to or alternate to determining the SoC, a Time to Empty(TtE) value may be read from a smart DC battery or may otherwiseinferred from data stored by the energy management schema. In oneexample the TtE represents the remaining operating time of therechargeable DC battery given its current state of charge, its chargecapacity and its expected rate of power draw and or its expected rate ofcharging. In a simple non-limiting operating example the charge managermakes a TtE estimate based on the present SoC of the DC battery, thecharge capacity of the battery and an assumption that the battery not berecharged and will be continuously discharged at its maximum dischargerate.

In step (615) the battery charging manager calculates an average stateof charge (ASoC) associated with a group of rechargeable DC batteriesbeing managed. The ASoC is determined by summing the SoC value eachrechargeable DC battery in the group and dividing the sum by the totalnumber of batteries in the group. In various operating modes the batterygroup of rechargeable DC batteries being managed includes onlystandalone rechargeable DC batteries, all rechargeable DC batteriesconnected to the power distribution and control module, including thoseassociated with power loads, only batteries or a particular type, e.g.only 12 volt batteries, or various combinations thereof. Selection ofthe battery group is dependent on various criteria including the loadand source priority of various external devices connected to the powerdistribution and control module, on polices operating on the batterycharging manager and or energy management schema, on user definedoperating modes, or the like. In step (620) the SoC value of eachbattery in the group of batteries being managed is sorted into SoC ordersuch as B₁ B₂, BN where B₁ is the battery with the lowest SoC and B_(N)is the battery with the highest state of charge. Other sort criteria areusable without deviating from the present invention.

The battery charging manager then executes an allocation loop (625)which operates to manage the battery group (B₁, B₂ . . . B_(n)) byallocating portions of the TCP to one or more of the rechargeable DCbatteries in the battery group. The TCP is allocated according toallocation criteria which may be set by default, may depend oninstantaneous operating conductions and or historic operatingconditions, may be user selectable, or may be set by policies of theenergy management schema or of the battery charging manager.Additionally the allocation criteria may depend on device priorities,battery type, and other data read from connected smart devices orotherwise available to the energy management schema or the batterycharging module.

In one non-limiting operating example, the allocation criteria chargesonly batteries in the group of batteries being managed that have a SoCvalue that are less than the ASoC. In another non-limiting operatingexample the allocation criteria considers the charge capacity of eachrechargeable DC battery in the group and weights TCP charge allotmentsaccording to battery charge capacity by allocating larger chargeallotments to batteries that have a larger charge capacity than isallotted to batteries that have a smaller charge capacity. For exampleif the battery group includes two rechargeable DC batteries each havingthe same SoC but having different battery charge capacities, the largercapacity battery is allocated more of the TCP than the smaller capacitybattery and the allotments are made in a manner that tends to increasethe SoC of each battery by an equal amount.

More generally the allocation criteria allocate unequal portions of theTCP to some or all of the batteries in the group of rechargeable DCbatteries being managed. In a preferred embodiment, the allocationcriteria allocate larger portions of the TCP to those batteries in thegroup of batteries being managed that have an instantaneous SoC valuethat is less that the ASoC of the group of batteries being managed. In apreferred embodiment the allocation criteria allocate portions of theTCP in a manner that tends to bring all of the rechargeable DC batteriesin the group of batteries being managed to the same ASoC value andthereafter to allocate portions of the TCP in a manner that tends tomaintain each battery in the group at a substantially equal SoC. In apreferred embodiment the allocation criteria includes a weightingalgorithm which weights TCP allocations to compensate for differences inthe charge capacity of the batteries in the group of batteries beingmanaged. In particular the weighting factor is selected to allocatepower in a manner that causes incremental increases in the SoC to besubstantially the same for each rechargeable DC battery in the groupirrespective of the charge capacity of each battery.

An exemplary non-limiting allocation Loop (625) sets a counter value (i)equal to 1 in step (630) where a different value of (i) is used toidentify each of the rechargeable DC batteries in the group of batteriesbeing managed. In step (635) the SoC value of a battery B_(i) iscompared to the ASoC of the group of batteries being managed. If the SoCvalue of a battery B_(i) is less than ASoC, the loop jumps to step (640)to allocate a portion of the TCP to the battery B_(i). If the SoC valueof a battery B_(i) is greater than ASoC, the loop jumps to step (655),described below.

Since the batteries are already sorted in SoC order in step (620), thefirst battery B₁ has the lowest state of charge. Nevertheless, the step(635) first checks to determine if the SoC of the battery B₁ is lessthan the ASoC and if so allocates a portion of the TCP to charge thebattery B_(i) in step (640).

As described above the allocated portion of the TCP may depend on thecharge capacity of the battery B_(i) and other factors. Additionally inone non-limiting example operating mode the allocated portion of the TCPis further weighted with respect to the magnitude of the differencebetween the SoC of the battery B_(i) and the ASoC. In one non-limitingexample embodiment the step (640) weights TCP allocations in a mannerthat allocates a larger portion of the TCP to batteries having smallinstantaneous SoC values than to batteries having larger instantaneousSoC values. Additionally the step (640) may weight TCP allocationsdifferently depending on other factors such as the source priority, onwhether the group of batteries being managed includes smart DC batteriesassociated with power loads, which already received a peak powerallocation in prior step (520) and other present and historic powerallocations.

Thus the allocation loop (625) operates in a manner that causes step(640) to only allocate portions of the TCP to batteries B_(N) that havean instantaneous SoC that is less than the ASoC of the group beingmanaged. Otherwise the step (635) causes the loop to jump to step (655)which is described below.

In step (645) the TCP is reduced by an amount equal to the portion ofthe TCP that was allocated to the battery B_(i) in the prior step (640).In step (650) the TCP is compared to zero and if the remainingunallocated TCP is equal to zero the loop (625) is stopped by jumping tostep (605) until the next time network is mapped, e.g. once every 20 to100 msec. If the TCP is non-zero, the loop jumps to step (655) where thecounter is incremented to and the loop jumps to step (660) where thevalue of (i) is compared to N wherein N is equal to the number ofbatteries in the group being managed. If (i) is less than or equal to Nthe loops jumps to step (635) to process the next battery B_(i). In thismanner the loop continues until (i>N) or until the remaining unallocatedTCP is equal to zero as determined in step (650) which causes the loopto jump to step (605) to wait for the next time the network is mapped.

In step (635) each time the SoC of a battery B_(i) is greater than theASoC, the loop jumps to step (655) which increments (i) withoutallocating a portion of the TCP to the battery B_(i). In step (655) the(i) value is incremented and the loop jumps to step (660) to compare the(i) value to (N) and then if (i≥N) the loop jumps back to step (635) toprocess the next battery B_(i). In cases where the SoC value of Bi isgreater than ASoC the loop continues to increment the (i) value in steps(665) without going to step (640) until (i>N) as determined in step(660). Thereafter the loop jumps to step (665) which can only happenwhen there is an unallocated portion of the TCP as determined in step(645) is non-zero.

In step (665) the unallocated portion of the TCP is allocated to theremaining batteries in the group being managed in equal portions. Inparticular each battery in the group being managed that was notallocated a portion of the TCP by the allocation loop (625) isallocation an equal portion of the unallocated TCP and the batterycharging manager process jumps to step (605) to wait for the next timethe power distribution and control module is remapped.

According to the present invention the specific portion of TCP allocatedto a battery B_(i) in step (640) can be varied by policies and othercontrol elements of the energy management schema or the battery chargingmanager and may dependent on a number of factors including, for example,battery chemistry, battery type, battery SoC, ASoC of the group ofbatteries being managed, the source priority of the available powersources, the magnitude of the TCP, whether the battery B_(i) is astandalone rechargeable DC battery or is connected to a DC power loadand other factors including the ASoC of the group of batteries beingmanaged and the number and type of DC power loads connected to powerdistribution and control module.

For example in cases where the TCP is large compared to the powerallocated to DC power loads in step (520) the allocation criteria usedin step (640) can be altered to take advantage of the excess chargingpower. In one example where the TCP is large compared to the powerallocated to DC power loads in step (520) the group of batteries beingmanaged is altered to include rechargeable DC batteries associated withpower loads or to disassociate rechargeable DC batteries associated withpower loads from the group of batteries being managed. In anotherexample where the TCP is large compared to the power allocated to DCpower loads in step (520) the allocation criteria is altered to a modethat attempts to more rapidly charge all of the batteries in the groupof batteries being managed such as by allocating the entire TCP to thelowest SoC battery in the group or by allocating the entire TCP to thebattery having the largest change capacity in the group, or the like.

Each of the steps set forth in FIGS. 5 and 6 are periodically repeatedat fixed or variable temporal frequencies. In a non-limiting embodimentthe power allocation steps of FIG. 5 are repeated every 20 to 100milliseconds but other repeat intervals are usable. In a non-limitingembodiment a new cycle of the steps set forth in FIGS. 5 and 6 isinitiated whenever certain changes in the power distribution and controlmodule are detected, e.g. whenever an external power device is added orremoved from the power distribution and control module, whenever a dropin input power amplitude or in bus power amplitude is detected, wheneverinput voltage or bus voltage falls below a threshold value, or the like.

In a non-limiting operating mode the controller data processing devices(220) (325) are operable to track power sensors associated with eachdevice port to track voltage current and power amplitude and to recordhistoric values for each external power device connected to the powerdistribution and control module. Thus in addition to data read fromexternal power devices such as peak and average or idle powerconsumption values and or current amplitude limits, or the like, thecontroller data processing devices are also operable to track actualpower consumption peaks, power consumption rates, and other parametersthat are usable to estimate present SoC and or TtE values and or predictfuture SoC and or TtE values based on historic use data as well as powersensor values and values read from connected devices.

Additionally by tracking historic values for each external power deviceconnected to the power distribution and control module and catalogingthose values by device type, device ID, peak and average powerconsumption and the like, the energy management schema is operable tocharacterize specific devices and or device types to improve estimatesof instantaneous input and output power conductions to improve powerdistribution management.

8.4 Peak Power Point Tracking

Referring to the power point tracking module (397) described above thePPT module (397) may comprise a separate operating mode that isinitiated either automatically or by user selection. This operating modeis especially desirable whenever the input power source is found to havea large input power amplitude variability as may be the case with aphotovoltaic solar blanket, wind turbine or vehicle power generationsystem. Moreover, operation of the PPT module (397) is better suited tocharging batteries than to fully powering loads.

The PPT module (397) includes a peak power tracking algorithm stored andoperable on the control module (325). The PPT module (397) uses aperturb and observe (P&O) PPT algorithm to track the input poweramplitude as a function of an output current set point of one of thecontrollable power converters (360). To find an output current set pointthat results in peak input power the (P&O) algorithm monitors the inputpower sensor (350) while incrementally varying the output currentamplitude of at least one DC to DC power converter (360). Thus aselected DC to DC power converter (360) is operated to incrementallymodulate current amplitude through a range while monitoring input powerat the input power sensor (350) with all the other DC to DC powerconverters set for zero current through put. After tracking powerthrough the selected current range a peak power operating point isselected and the selected DC to DC power converter is set to a currentamplitude operating point corresponding with the peak input power level.If the input power source delivers substantially non-varying or narrowlyvarying input power signal amplitude, all of the DC to DC powerconverters may be set to the same current set point associated withmaximizing input current amplitude. If the input power signal amplitudeis temporally variable the (P&O) algorithm may be repeated at therefresh rate e.g. using the same DC to DC power converted each time orthe (P&O) algorithm may be repeated for each DC to DC power converter.In either case the DC to DC power converter current amplitude operatingpoint may be refreshed at the refresh rate, such as every 20 to 100msec.

As will be recognized by those skilled in the art, the present inventionallocates peak power demand to each power load being power in step(520). However not every power load being allocated peak power uses thefull power allocated. In cases where the power load is associated with asmart rechargeable DC battery as described above, a portion of the peakpower allocation is stored by the smart rechargeable DC battery. Morespecifically any of the peak power allocated to a power load that is notused to power the load merely recharges the rechargeable DC batteryassociated with the power load thereby increasing its SoC. Thus whenevera DC power load fails to use its peak power demand for an extendedperiod the rechargeable DC battery associated with the power load tendsto become fully charged. For this reason, the energy management schemamay be further configured to weight the allocation of DC power to powerloads in step (520) according the SoC of rechargeable DC batteryassociated with the power load. In one non-limiting example step (520)may include allocating less than the peak power demand or in some casesnot allocating any power to a DC power load when the SoC of rechargeableDC battery associated with the power load is nearly 100% orsignificantly higher than the ASoC of other rechargeable DC batteriesconnected to the power distribution and control module.

In a further operating mode example of the power distribution andcontrol module (200), when the only available input power source is oneor more rechargeable DC batteries connected to or connectable to thepower bus (210), the energy management schema is operable to connect oneor more rechargeable DC batteries to the power bus to power loads. As afirst choice only a single standalone rechargeable DC battery isselected as an input source. In other operating modes power may be drawnfrom other rechargeable DC batteries connected to or connectable to thepower bus (210) including DC batteries associated with low prioritypower loads.

In one operating mode the available standalone rechargeable DC batteriesthat are usable as input sources are sorted in SoC order and thestandalone rechargeable DC battery having the highest SoC is exclusivelyconnected to the power bus to power loads and exclusively used until itis fully discharged or until a more suitable input power source becomesavailable. If the first battery becomes fully discharged then therechargeable DC battery having the next highest SoC is used exclusivelyuntil it is fully discharged and so on until all the availablestandalone rechargeable DC batteries are discharged. Thereafterrechargeable DC batteries associated with low priority power loads areused to power higher priority power loads as needed.

Alternately the energy management schema may monitor the SoC of all thestandalone rechargeable DC batteries usable as an input power source andalternate which of the available standalone rechargeable DC batteries isused to power loads in a manner that essentially manages the SoC of allthe available standalone rechargeable DC batteries usable as input powersources in a manner that attempts to keep the SoC of all the standalonerechargeable batteries equal.

It will also be recognized by those skilled in the art that, while thepresent invention has been described above in terms of preferredembodiments, it is not limited thereto. Various features and aspects ofthe above described invention may be used individually or jointly.Further, although the invention has been described in the context of itsimplementation in a particular environment, and for particularapplications, e.g. as a soldier power manager or a portable batterycharger, those skilled in the art will recognize that its usefulness isnot limited thereto and that the present invention can be beneficiallyutilized in any number of environments and implementations where it isdesirable to monitor and manage power resources in a manner thatsimultaneously powers loads and recharges batteries. Accordingly, theclaims set forth below should be construed in view of the full breadthand spirit of the invention as disclosed herein.

What is claimed:
 1. A power distribution and control module comprising:an input device port interfaced with a DC power source wherein the DCpower source has a source operating voltage; a plurality of outputdevice ports with one of more of the plurality of output device portsbeing interfaced with a different DC power load wherein each DC powerload has a load operating voltage; a plurality of unidirectional DC toDC power converters, wherein each DC to DC power converter includes aninput terminal electrical interfaced with the input device port and anoutput terminal electrically interfaced with a different one of theplurality of output device ports; an input power sensor disposed tosense one of voltage amplitude and current amplitude at each of theinput device port and with the input terminal and with each of theplurality of unidirectional DC to DC power converters; a plurality ofoutput power sensors each disposed to sense one of voltage amplitude andcurrent amplitude corresponding with the output terminal of a differentone of the plurality of DC to DC power converters and with the outputdevice port electrically interfaced with the output terminal thereof; anelectronic control module comprising a data processor and an associatedmemory module wherein the data processor is in communication with eachof the plurality of unidirectional DC to DC power converters to submitcontrol signals thereto, with the input power sensor and with each ofthe plurality of output power sensors to receive sensor signalstherefrom and; an energy management schema program operating on the dataprocessor to manage an instantaneous voltage conversion settingcorresponding with providing a desired DC output voltage at each of theplurality of output device ports wherein the desired output voltage ismatched with the load operating voltage of a DC power load electricallyinterfaced therewith.
 2. The power distribution and control module ofclaim 1 wherein the DC power source comprises one of a DC power supply,DC power generator, an electrochemical energy storage device and the DCpower load corresponding with each output device port comprises any oneof a DC power load and a rechargeable electrochemical energy storagedevice.
 3. The power distribution and control module of claim 2 whereinthe energy management schema is further operable to manage aninstantaneous current conversion setting corresponding with providing adesired DC output current amplitude at each of the plurality of outputdevice ports wherein the desired output current amplitude can beindependently varied at the output terminal of each of the plurality ofDC to DC power converters.
 4. The power distribution and control moduleof claim 3 further comprising a Power Point Tracking (PPT) programmodule operating on the data processor configured to determine a peakpower operating point while incrementally varying output currentamplitude over a range on a selected one of the plurality of DC to DCpower converters and thereafter fixing the peak power operating point bysetting a current conversion setting corresponding with selected one ofthe plurality of DC to DC power converters to the output currentamplitude corresponding with the peak power operating point.
 5. Thepower distribution and control module of claim 1 further comprising: acommunication interface device in communication with the data processor;a communication channel extending between the communication interfacedevice and each of the input device port, the plurality of output deviceports; wherein the energy management schema operates to communicate witheach device port over the communication channel to determine if a DCpower source is interfaced with the input device port and if so todetermine power characteristics of the DC power source and to determineif a DC power load is interfaced with each plurality of output deviceports and if so to determine power characteristics corresponding witheach DC power load.
 6. The power distribution and control module ofclaim 4 wherein at least one of the plurality output device ports isinterfaced with a rechargeable DC battery further comprising a batterycharging manager program operating on the digital processor, wherein thebattery charging manager program operates to allocate low poweramplitude signals to the rechargeable DC battery.